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Distribution Statement A: Approved for Public Release; distribution unlimited
UNCLASSIFIED
Additive Manufacturing Methods, Techniques, Procedures, &
Applications - Enabling Technologies for Military Applications
Distribution Statement A: Approved for Public Release; distribution unlimited
Mr. Ralph Tillinghast & Mr. James Zunino
U.S. Army RDECOM-ARDEC
Picatinny Arsenal, NJ
UNCLASSIFIED
Distribution Statement A: Approved for Public Release; distribution unlimited
UNCLASSIFIED
• Additive Manufacturing gives capability to print
parts at point of use in theatre
• In order to print parts, 3-D model data and
machine manufacturing instructions are required
(CAD + CAM)
• Pedigree of part is conditional upon certified
model and manufacturing data
• DoD wants soldiers to have capability to make
parts in theatre using additive manufacturing
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Vision: Innovative Armaments Solutions for Today and Tomorrow
Advanced Weapons – line of sight/beyond line of sight fire, non line of
sight fire, scalable effects, non-lethal, directed energy, autonomous
weapons
Ammunition – small, medium, large caliber, propellants, explosives,
pyrotechnics, warheads, insensitive munitions, logistics, packaging; fuzes,
environmental technologies and explosive ordnance disposal
Fire Control – battlefield digitization, embedded system software, aero
ballistics and telemetry
Armament Research, Development and Engineering Center
Mission: To develop and maintain a customer focused, world-class workforce that will
execute, manage and continuously improve integrated life cycle engineering
processes required for the research, development, production, field support and
demilitarization of munitions, weapons, fire control and associated items.
ARDEC Provides the Technology for Over 90% of the Army’s Lethality and Provides Significant Support to
other Services’ Lethality
Research
Development
Production
Field Support
Demilitarization
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What is Additive Manufacturing?
Stone Age Bronze Age Iron Age Early subtractive processes Early additive processes Consolidation of subtractive processes
To add or subtract… that is the question
Additive Manufacturing (AM) is the process of joining materials to make
objects from 3D model data, usually layer upon layer, as opposed to
subtractive manufacturing methodologies. (ASTM F2792-12a)
Machining
20th Century Processes
Subtractive Additive
Forging Direct digital (additive) manufacturing Sintering
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Materials for AM: Powder to
Product
Characterization Consolidation Confirmation
Fundamental understanding of the impact of all
processing parameters is essential at each step
Expertise in each aspect of the manufacturing
process for transition to the industrial base
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Weapon Systems/Subsystems: Remote Weapon Systems,
UGVs, UAVs
Soldier Systems
Spare Parts
Life Cycle Optimization: Parts
Replacement & Improvement, Embedded
Tracking & Monitoring
Munitions & Missiles: Metal Parts,
Fuzes, Energetics, Warheads
Army Opportunities
Test & Analysis: Models, Test
Platforms, BITs, Prognostics&
Diagnostics
Training & Planning
Aviation Systems
To be successful, the Army needs a strategy make AM available to users
There are opportunities for AM to impact all Army systems
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Reduced manufacturing costs - Rapid Prototyping
Systems Resilient Engineering / Reduced reliance of proprietary system
- IP Protection, Data Rights, Database Access, TDP ownership(s)
Conformal designs & better interior volume utilization - Reduced size & weight
- Electronics/mechanics applied to interior surface of the munitions and/or onto Warfighters
- More room for added components
Affordable components for smaller munitions items
- Sensors, antennas, Fuzes, etc.
Mission tailored - Direct from CAD to prototype
- Performance tailored to the materials employed
Versatile - Can include, electronics, MEMS, electromechanical, optoelectronics and power sources
Easier transition from single prototype to large scale manufacturing
Faster material release - Factory in a truck, Fabrication in theatre, Just in time
More immune to obsolescence
Potential for less reliance on off-shore sourcing
New Techniques / Methodologies for Munitions Design / Integration / Fabrication
Why Are We Interested?
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Current RDECOM AM Capability
ECBC
CERDEC
TARDEC
ARDEC ARL
Aviation and Missile Technology
Prototyping & Integration
Processes
Total # of
machines
• Fused Deposition
Modeling
• Vat Polymerization
• Polymer Jetting
• Dimatix
• 10 machines in total
Materials
Applications
• ULTEM*, ABS
(Acrylonitrile Butadiene
Styrene), PLA
(polylactide)
• Prototypes, electronics
AMRDEC
Army Research Lab
Processes
Total # of
machines
• Polymer extrusion
• Vat Polymerization
• Powder Bed Metal
• InkJet
• Aerosol Jet
• Micro Pump Deposition
• Non-Commercial Systems
• 13 machines in total
Materials
Applications
• Polymers, Metals,
Ceramics & materials for
printed electronics
• 6.1-6.2 materials and tech
development
C4ISR Technology Prototyping &
Integration
Processes
Total # of
machines
• Polymer jet printing
• 1 machine
Materials
Applications
• photopolymer
• Engineering
development
prototyping
Armaments Technology Prototyping & Integration
Processes
Total # of
machines
• Printed Electronics, Polymer
Extrusion, Vat Polymerization,
Powder Bed Polymer and Metal
Fusion
• 46 different machines / capabilities
Materials
Applications
• Epoxy, ABS, PLA, Wax, 17-4 SS,
300 Maraging Steel, Nylon,
Alumide, PE Materials, etc
• Casting molds, Prototypes,
Munitions' Components
Ground and Support Systems
Technology Prototyping & Integration
Processes
Total # of
machines
• Direct Metal Deposition
• Fused Deposition
Modeling
• Selectively depositing
liquid binding material
• 4 machines in total
Materials
Applications
• Fe, Co, Ni, Ti, and
Cermets
• Coating / part repair,
3D printing, & Multi-
material joining
Chemical and Biological Technology
Prototyping and Integration
Processes
Total # of
machines
• Polymer extrusion
• Vat Polymerization
• Powder Bed Polymer and Metal
• Polymer Jetting
• Binder Jetting
• 13 machines in total
Materials
Applications
• ABS, ULTEM*, PC, PPSF
(polyphenylsulfone), Nylon 11,
Nylon 12, Steels, Cobalt
Chrome, plus more.
• Prototypes, unique fixtures,
end-use items, Tooling and
tooling inserts
* ULTEM - Resin family of amorphous thermoplastic polyetherimide (PEI) resins offers outstanding elevated thermal resistance, high strength
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Rapid Tooling/Fielding
2012 2014 2016 2018 2020
Sustainment-Centric:
Tooling and Repair
Process Substitution:
Alternative manufacturing for
conventional manufacturing processes
Process Centric
Process drives
design and
performance
Additive Manufacturing –
Applications Roadmap
Substitute/Replace
Novel Designs
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The Additive Manufacturing
Challenge
New additive manufacturing processes bring the promise of enhanced
performance with the flexibility of historical additive processes like casting and
welding
• Current additive processes can produce
– Tailored material combinations
– Functionally gradient materials
– Opportunity for material customization
– Ability to produce unique geometries
• Each part is unique, therefore certification of the material, process, and
qualification are paramount
• A roadmap must recognize both the opportunity and the challenges presented
by the uniqueness of the process
Welding, sintering, and casting provide excellent benchmarks for additive
manufacturing, since they have similar requirements for process qualification
and part uniqueness for part acceptance
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Summary of Major Technology Challenges
• Each part is unique, therefore certification/qualification of the
material and process are paramount
– Part quality is tied closely to process parameters, therefore processing conditions must be
defined to ensure a quality part
– Because industry views AM process data as proprietary, the process data needed to
guarantee part performance is not available and is held as IP
• AM standards are not available – much of work is still in progress
– The relationships between materials, process and performance have not been established,
so standards development is slow
– In specific cases, companies have established their own standards, which they retain as
proprietary
• There are a limited number of machines, additive processes and
materials available from the equipment manufacturers
– Material performance is not always “as advertised” on the equipment mfr. Data sheets and
not fully characterized for all use cases
• No full materiel release – no systems in the field using additive parts
– The few cases where additive has been used to produce a part are on an exception basis:
SOCOM, REF for spares, repairs and/or tooling
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The RDECOM Community has developed a plan for five year progressive stages of
adoption, supported by four pillars of investment:
Rapid Fielding – Point
of Use manufacturing
Tooling and Repair
Part Substitution
FY15-19 FY20-24 FY25-29+
Pillar 1: Material and process certification and qualification
Pillar 2: Army Additive Manufacturing Knowledge-base
Pillar 3: Machine Technology and Material Improvements
Pillar 4: Transfer technology to the industrial base and field
Part Alternative Process Alternative Product Alternative
Process Substitution
Primary manufacturing
Novel Designs
Novel Materials
Level of complexity from low to high, evolving from part to system,
and from early adopters to traditional acquisition
Army AM Investment Strategy
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DOD heavily investigating the utilization of Additive Manufacturing for
weapon systems.
Transportation, storage, and operational environments must be
considered.
DOD represents unique environment for printed electronics utilization.
- High G loads
- Extreme Temperature and Humidity ranges
- High shock and vibration loads
- Extended Periods of dormancy (+20 Years)
Limited data for failure mechanisms, failure rates, reliability, survivability.
Need for high reliability devices in DOD applications.
Military Considerations
UNCLASSIFIED
Systems / Sub-System Efforts
Munitions & Warheads
Printed Super-capacitors
Flexible Power Sources
Detonation Sensors
Armaments/Munitions Prognostics & Diagnostics
HERO Safe RFID Tags
Instrumentation for Training & Simulation (MILES,
TAGS, P&D, etc.)
Fuze Systems / Components
Printed PROX / Fuze Antennas
Remote Weapon and Unmanned Systems Integration
UNCLASSIFIED
Process Development Efforts
Materials Development (Inks, Powders, Binders, etc.)
Ink Formulations
Recycling / material Re-use
Additive Manufacturing Techniques
Integration of 2D & 3D Printing
Integration with Munitions, Warheads & Energetics
Equipment modification / Development (i.e. multi-head /material
capabilities)
Deposition Techniques
Testing and Evaluation
- Qualification
- High –G survivability
- Reliability
- Long-term Survivability
Interconnects / Solderability
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ARDEC 3D Printing Capabilities
• Material Printers / 3D Printers
- Plastics (PLA, ABS, other)
- Inks
- Powder-Binder
- FDM
- LOM (Laminates)
- Direct Laser Sintering (Metals & Plastics)
- Several Custom & Multi-material systems
• 3D Scanners
- Photo, Digital, Laser, etc.
• 3D CAD / Modeling
- NetFab
- MasterCam
- Pro-E
- Maya
- Solid Works
- Sketch-Up
- Adobe Design Suite
- 3D Studio Max
- Z-Edit
- Others
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PEEMS Capabilities
• Ink Jet – Dimatix, Epson, PixDro
• Aerosol Jet – Optomec
• Micropen / Direct Write / DipPen – Sonoplot, EFD, M3P, NanoInk, Controlled Syringe, nFD
• MicroPump
- nScrypt
• Screening & Stenciling
• Etching & Routing
• Transfer & Plating
• Multi-Axis Module Manufacturing Platform (M3P)
• Numerous 3D Capabilities
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The M3Platform is a part of the
concepts being developed at
ARDEC looking at new and
innovative production methods
to better meet future Army
needs. By combining multiple
manufacturing techniques with
direct write and additive
manufacturing capabilities,
ARDEC’s goal is to have flexible
and low cost capabilities for
prototyping and production. Just-
in-Time Manufacturing and Fab-
in-the-Field concepts are being
explored.
Multi-Axis Multifunctional Manufacturing Platform M3P
ABS extruder tool module
Router tool module
Syringe deposition tool module
Camera/inspecti
on tool
module 4-point robe/inspection
tool module
Spray/encapsulant
tool module
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Unique AM Technology -
SuperScrypt
SuperScrypt
With Scan-to-print capability, the SuperScrypt can deposit on complex curves,
or build 3D shapes from scan data.
Inverse kinematics enabled 6-axis motion control allows for true 3D printing
instead of stacking 2D layers. Robust hardware allows for +/- 200nm precision.
Dubbed the SuperScrypt, this multi-technology printing
system is the only one of its kind. The systems is
based on nScrypt processing controls and software,
which are fully open for manipulation (variation of
processing parameters). This system includes:
•Line Scanning
•Thermoplastic Extrusion (up to 400)
•Thermoset Deposition
•Ink Deposition
•6-Axis Motion Control
•Tool Switching
•Pick-n-Place
To be added in FY15:
•Micro-Sprayer
•Micro-Milling
•Laser Sintering
•Aerosol Jet Deposition
•Micro Cold Spray Deposition
•Materials Hopper
•Auger
Tools can be
added as needed
Conformal
Printing
Fabricate a
functioning
device
(0 to 2,000,000cP,
with pico-liter control)
Scan-to-Print
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PROBLEM:
• ARDEC engineers received the new GD—PRC155 Radio to
integrate into our fire control systems.
• The radio had a special connector and when ARDEC
engineers tried to order it…
• The connector was on 3-4 month back ordered and at a cost
~$300 each, with a min purchase of 50 ($15,000).
SOLUTION:
• ARDEC engineers modeled and then printed the connector
on an in expensive in-house 3D printer.
PAYOFF:
• Cable fabricated & tested with-in 1 day!
• Avoided 3-4 Month program slip
• ~$14,500 savings in program cost
• 3D Printed Part: ~$0.25, 2 hr modeling time & 1 hr print
time
Additive Manufacturing
Success Story
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Additive Manufacturing
Success Story
PROBLEM:
• Novel design of Wrap Fins on Next Generation PGM required
custom fixtures, required wall thickness makes casting very
difficult and costly, and different variants are required for wind
tunnel testing.
• Geometries of Wrap Fins lead to cracking with conventional
manufacturing methods (EDM).
AM SOLUTION:
• ARDEC Engineers were able to use Additive Manufacturing via
metals selective laser sintering to fabricate Wrap Fins for wind
tunnel testing.
• Alternative designs and variants were fabricated with limited
turn-around time that would be almost impossible with
conventional metals manufacturing processes.
BENEFIT / SAVINGS
• Devices fabricated and tested in days vs. months using
conventional procedures
• Enhanced design capabilities that could only be fabricated via 3D
printing (unique geometries ).
• Cost Savings
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PROBLEM:
• Warfighter need to reduce weight of PackBot to meet weight
requirements for man portable system.
• iRobot proprietary models and design files.
• Original Flippers are cast metal and machines holes with plastic
coatings for environmental protection.
AM SOLUTION:
• Used 3D scanning capabilities to rapidly create 3D models of best
candidate parts for weight reduction.
• Used CAD software to redesign with reduced weight and material
alternative designs (flipper & support arms) that could not be
fabricated cost effectively with traditional processing (casting,
machining).
BENEFIT / SAVINGS
• Devices fabricated and tested in days vs. months
• Enhanced design capabilities that could only be fabricated via 3D
printing (unique geometries ).
• 45% Volume/Weight reduction (242.30 cm3 reduced to 134.84 cm3)
Additive Manufacturing
Success Story
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“Soldier to Solution”
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Additive Manufacturing Library A Digital Repository of Robotic Concepts and Designs for Use by the Warfighter
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Mini Track Bot
Designed as an ultra portable bot
for camera surveillance in any
terrain. Operated by a small
touch screen controller with
adequate range for the soldier to
standoff at a safe distance.
Weight: 2 pounds
Dimensions: 8” x 7” x 5”
Status: Approved for printing
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Provide the Army with state-of-the-art technologies
Weight / Volume savings
Cost effective prototyping & fabrication techniques
Increased force effectiveness and reduce operations, support,
maintenance, and liability costs
Transition from scheduled to condition based maintenance
Increase Army readiness by reducing equipment downtime
Increase safety by providing ammunition assurance
Reduce reliance on proprietary systems
Systems Resilient Engineering (IP Protection, Data Rights, Database
Access)
Improved asset protection
Paradigm Shift in Energetics Development, Production & Testing
Improved Testing Capabilities
Improved Training & Planning Operations
Optimized R&D / Systems Engineering
Warfighter Benefits
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3D Printing (Additive
Manufacturing) has had an
impressive record.
Combining 3D Printing with
Printed Electronics will create a
disruptive approach with the
Cyberfacturing of ANY
electronic device.
The biggest benefit will be seen
by the DoD and consumers.
When entrepreneurs can begin
to inexpensively produce the
dreams of their imaginations,
the manufacturing revolution will
begin.
Imagine a day when large automobile factories
are replaced by Dealer Cyber Factories.
Reference: Ken Church - UTEP
The Future !?!
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Ralph Tillinghast US Army ▪ ARDEC ▪ RDAR-MEE-M
Ralph.c.tillinghast.civ@mail.mil
973-724-2095
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